The present disclosure generally relates to electric machines and particularly to permanent magnet machines providing high torque density.
This section introduces aspects that may help facilitate a better understanding of the disclosure. Accordingly, these statements are to be read in this light and are not to be understood as admissions about what is or is not prior art.
Currently, there is great social interest in increasing the efficiency of power magnetic devices such as electric generators and motors, which are used in applications such as wind energy turbines and hybrid and/or electric vehicles. For example, there has been an ongoing desire to improve conventional permanent magnet synchronous machines (PMSMs). PMSMs have historically been present in specialty applications of small ratings or in very high speed applications, for example, in excess of 20,000 rpm. Examples include spindle drives and flywheel energy storage machines. Advancements in the late 20th century in high energy permanent magnets increased interest in PMSMs. For example, utilization of PMSMs in full and hybrid electric vehicles has drastically increased in the last several years, where it is believed to have accounted for sixty-five percent of electric machines topologies used. Reasons for this increase are believed to be related to the drawbacks that other machine topologies suffer from. Direct Current (DC) machines, although capable of providing high stall torque, suffer from degradation of carbon brushes, which creates an ongoing maintenance issue. Induction machines exhibit the advantage of low cost and high robustness but need sophisticated control to accommodate wide speed operation. Reluctance machines suffer from low efficiency and relatively low power density. PMSMs on the other hand are typically known for their high torque density for a given loss, high reliability, and high system efficiency.
PMSMs can in general be classified as Surface Mounted Permanent Magnet Synchronous Machines (SM-PMSMs), or Interior Permanent Magnet Synchronous Machines (IPMSMs), with a variety of different forms coming from these general structures. The SM-PMSMs have permanent magnets placed on a surface of a rotor, where the permanent magnets are secured in position by either gluing them or wrapping an inert material around them. In IPMSMs, the permanent magnets are buried in the rotor back iron which provides mechanical protection to the permanent magnets.
In traction applications, one of the main requirements for an electric motor is to be capable of maintaining a wide constant power speed range (CPSR). Numerous ideas have been proposed to improve the efficiency of PMSMs such as enhanced excitation current control methodologies and a structural modification to the machine. Modifying the machine structure to improve the CPSR performance has been considered in a number of published research works.
Increasing saliency increases what is commonly known as saliency or reluctance torque, which contributes to the overall torque production in addition to the torque produced by the permanent magnet. One technique used to increase the saliency in an SM-PMSM is by using flux barriers. Another approach relies on tapering the machine's steel to create an asymmetry. Another approach to create an asymmetry for the purpose of enhancing the performance of a hybrid machine, with both a reluctance rotor and a permanent magnet rotor sharing the same shaft and stator, is by having the reluctance rotor axis shifted with respect to the permanent magnet rotor axis.
In view of the above, there are ongoing efforts to improve the efficiency of PMSMs, and it would be desirable if a PMSM was available that was capable of providing improved operational efficiency and reduced manufacturing cost.
Over the past few years, effort in the prior art has been expanded to develop a reluctance machine with high efficiency and high torque production capability relative to physical size. A reluctance machine is a type of magnetic device, e.g., a motor, where magnetic poles are induced in a rotating non-magnetic member (i.e., a rotor) by at least one winding in a stationary member (i.e., a stator). The rotor is typically provided with a plurality of salient (i.e., outwardly projecting) poles. The poles are induced by applying electrical current to the winding.
Exemplary prior art reluctance machines with distributed windings is depicted in
Referring back to
Attempts to improve the performance of the synchronous reluctance machines are typically associated with design of the rotor assembly 14 of the reluctance machine 10 such that it will result in improved performance One category of performance is torque density which is the amount of torque that is generated relative to the physical size or mass of the machine for a given amount of loss. The rotor assembly 14 depicted in
One approach to decrease power loss in one rotational direction is to employ an asymmetric reluctance machine (i.e., as compared to symmetric reluctance machines). Referring to
The rotor assembly 140 includes a rotor core 150 and a plurality of outwardly protruding poles 160. Each of the plurality of outwardly protruding poles 160 has an asymmetrical shape, pointed out by the shape of pole tapers 164. The rotor assembly 140 also includes a shaft 170 positioned at the center of the rotor core 150.
The asymmetrical nature of the rotor assembly 140 improves the power loss of the reluctance machine in one direction (the main rotational direction of the reluctance machine). While this improvement is advantageous, additional improvement is needed.
Therefore, there is a need for a to power magnetic machine that improves output torque density based on the relationship between the rotor shape and the stator.
A permanent magnet machine is disclosed. The machine includes a stator assembly which includes a housing, a stator backiron, a plurality of windings disposed in the housing coupled to a plurality of electrical connections, and a plurality of stator teeth coupled to the stator backiron. The permanent magnet also includes a rotor assembly which includes a center configured to couple to a mechanical coupling member disposed about the center, an inner core, positioned around the center, an outer core disposed around the inner core, and a plurality of outwardly protruding poles radially located within the stator assembly each outwardly protruding pole having an outer surface adjacent to at least one tooth of the plurality of teeth. Each outer surface of each outwardly protruding pole having a rotor tooth extending from the outer core and a permanent magnet disposed next to the rotor tooth forming the outer surface that is substantially continuous.
A drive system is disclosed. The drive system includes a voltage source, and a permanent magnet machine as described above and structured to be coupled to a mechanical load.
For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.
A novel electric machine has been developed which improves torques output in one direction as compared to known prior art power magnet machines. In particular, aspects of the present disclosure provide an asymmetrical permanent magnet synchronous machine (A-PMSM) architecture that employs rotational asymmetry to reduce machine mass, cost, and power loss in constant power speed range (CPSR) applications.
Referring to
The power converter 74 includes power inputs which are connected to the conductors 73a and 73b to receive one of a DC power, a single-phase electrical current or a multi-phase electrical current (wherein, in a multi-phase AC configuration there are corresponding conductors). Additionally, the power converter 74 includes an input which is coupled to an output 79 of a converter controller 78, described further below. The Power converter 74 also includes three outputs representing three phases with currents that are each separated by 120 electrical degrees. Each phase is provided on a conductor 75a, 75b, and 75c. It should be noted that a common neutral line for return of each phase of the electrical currents is not shown and may or may not be present. It should also be appreciated that the power converter 74 may produce more or less number of phases (i.e., more or less than three phases).
The drive system 70 also includes an A-PMSM 76 which is coupled to the power converter 74. The A-PMSM 76 may include a plurality of inputs which are connected to the conductors 75a, 75b, and 75c. The inputs are coupled to respective windings, described further below (see
The drive system 70 also includes the converter controller 78 which is coupled to the A-PMSM 76 and the power converter 74. The converter controller 78 includes an input which is coupled to the signal output 77a of the A-PMSM 76. The signal output 77a represents a feedback signal from the A-PMSM 76 that can be used to control the power converter 74. In one embodiment, this feedback signal is the position of the rotor assembly 240 (see
These sensors may be positioned on the rotor assembly 240 (see
It should be appreciated that in an alternative embodiment the power converter 74 may be avoided and the A-PMSM 76 powered directly by an appropriate voltage source 72.
It should also be appreciated that a synchronous reluctance machine is different than the A-PMSM 76, in that windings positioned in the rotor are short circuited to assist in startup (often referred to as damper windings). In such a configuration, the reluctance machine can be operated directly from a polyphase voltage source; thereby eliminating the need for power electronics or controls. However, the drive system 70 depicted in
It should be appreciated that while the A-PMSM 76 of
Referring to
The rotor assembly 240 includes an inner core 250 which could be made from a magnetically inert material and an outer core 255 which terminates in a plurality of outwardly protruding poles 258 (which can also be made from magnetic steel). Each of the plurality of outwardly protruding poles 258 forms an asymmetric arrangement, pointed out by a rotor tooth 260 and a permanent magnet 263. The permanent magnets can be made from ferrite, samariam cobolt, neodynium iron boron, or other magnetic material known to a person having ordinary skill in the art. The rotor assembly 240 also includes a center configured to receive a shaft 270 (or also referred to as a mechanical coupling member) positioned at the center of the inner core 250. The shaft 270 is configured to be coupled to a mechanical load (e.g., the mechanical load 80 depicted in
The ratio of circumferential portions defined by the rotor tooth and the accompanying permanent magnet 263 define the asymmetrical nature of the A-PMSM.
While a curved surface is depicted in
It should be appreciated that it is the flux density profile on the stator teeth 220 over the outwardly protruding poles 258 that define the pole asymmetry. It should be noted that the flux density in the stator teeth 220 and the outwardly protruding poles 258 are correlated. However, the flux density in the stator teeth 220 becomes higher as the teeth conduct the flux over the slots between the teeth 220.
One goal is to cause the flux profile of the stator teeth 220 that are over the outwardly protruding poles 258 to be such as to be favorable from torque production and loss viewpoints, particular as operating conditions (speed, required torque) change.
Additionally, the shape of the rotor assembly 240 and in particular the shape and characteristics of the asymmetry defined by the rotor tooth 260 and permanent magnet 263 of the outwardly protruding poles 258 in relationship to the stator assembly 210 and in particular to its teeth 220, results in a flux density profile over the surface of the outwardly protruding poles 258 and in particular over the outer surfaces of the rotor tooth 260 and the permanent magnet 263 so as to be favorable from a torque production and loss viewpoints.
Therefore, the asymmetry is designed 1) to generate a flux density profile over the poles (i.e., the outer surfaces of the rotor tooth 260 and the permanent magnet 263) of the outwardly protruding poles 258 which is favorable for torque production; and 2) to have this profile be adjustable with operating conditions so as to facilitate a wide speed range.
Referring to
It should be observed that the rotor shape of a conventional PMSM substantially achieves the same flux density over the poles irrespective of the direction of the desired torque. Thus, the induced field is substantially the same with the rotor assembly 14 rotating in the direction of arrow 36 or 38 (see
In comparison, the rotor assembly 240 (see
Since a higher amount of output torque is produced, the A-PMSM of the present disclosure can be smaller, lighter, and less costly as compared to a conventional PMSM producing the same output torque. In contrast, for the same size PMSM, the A-PMSM of the present disclosure can generate a higher level of output torque in one direction (e.g., direction 142b as shown in
Lower torque ripple can result in a smoother operation of the A-PMSM even in lower speeds.
Referring to
Referring to
In operation, with respect to
Alternatively, the A-PMSM 76 can be configured to convert mechanical power to electrical power. In this configuration, the mechanical load 80 is providing mechanical power to the A-PMSM 76 and in turn, the A-PMSM 76 converts the mechanical power to electrical power which is provided to the power converter 74 or directly to the voltage source 72.
While the asymmetrical rotor concept described here has been applied to a permanent magnet machine, it is recognized that the same concept could be applied to other types of machines which use a continuously rotating magnetic field, wherein the rotor rotates in synchronism with the field, including wound rotor synchronous machines.
Those skilled in the art will recognize that numerous modifications can be made to the specific implementations described above. Therefore, the following claims are not to be limited to the specific embodiments illustrated and described above. The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
The present application is related to and claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/188,237 filed Jul. 2, 2015, the content of which is hereby incorporated by reference in its entirety into the present disclosure.
This invention was made with government support under NNX12AM04G awarded by National Aeronautics and Space Administration and Contract No. DE-EE0005568 awarded by the U.S. Department of Energy to the Hoosier Heavy Center of Excellence Fellowship. The government has certain rights in the invention.
Number | Date | Country | |
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62188237 | Jul 2015 | US |